Longitudinally Clamped EV Battery Pack for Higher Energy Density
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Solution Overview
Problem
Existing battery designs suffer from reduced energy density due to mechanical clearances between cross-members and assemblies, which also compromise resistance to lateral impacts.
Innovation Solution
A battery design with cross-members and assemblies that are directly mounted and clamped together without mechanical clearance, using thinner cross-members and flexible materials to enhance energy density while maintaining impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cross-members are dimensioned to resist buckling with sufficient thickness, then impact resistance is improved, but energy density deteriorates due to increased spacing between assemblies
Solution Approach 1:
The patent applies preliminary action by pre-defining compartments in the casing during casing formation, which guides the precise positioning of assemblies and cross-members during assembly. This eliminates the need for large mechanical clearances, allowing thinner cross-members to be used while maintaining structural integrity and impact resistance, thereby improving energy density.
Solution Approach 2:
The patent changes the parameter of cross-member thickness by using thinner cross-members (less than 20 mm, preferably less than 10 mm) compared to conventional thick cross-members. This is made possible by the pre-defined compartments that ensure proper positioning and load distribution, allowing the structure to maintain strength while reducing the space occupied by structural elements, thus improving energy density.
2Ease of manufacture
If mechanical clearances are maintained between cross-members and assemblies, then ease of assembly is improved, but energy density deteriorates due to wasted space
Solution Approach 1:
The patent applies preliminary action by pre-forming compartments in the casing that define exact positions for assemblies and cross-members. This preliminary structuring allows components to be assembled tightly without requiring mechanical clearances for alignment, as the compartments themselves provide the positioning guidance, thereby eliminating wasted space and improving energy density.
Solution Approach 2:
The patent uses the pre-defined compartments as an intermediary structure that mediates between the need for precise positioning (ease of assembly) and the need to minimize spacing (energy density). The compartments serve as guides that enable tight tolerances and minimal clearances while still facilitating the assembly process.
3Quantity of substance
If thinner cross-members are used to improve energy density, then space for assemblies is increased, but impact resistance deteriorates due to reduced structural strength
Solution Approach 1:
The patent applies preliminary action by pre-defining compartments in the casing that provide structural support and positioning guidance. This preliminary structuring allows thinner cross-members to be used because the compartments themselves contribute to the overall structural integrity and load distribution, compensating for the reduced thickness of individual cross-members while maintaining buckling resistance.
Solution Approach 2:
The patent effectively creates a composite structure where the casing with pre-defined compartments works together with the thinner cross-members and assemblies. The combination of these elements creates a synergistic system where the compartments provide additional structural support, allowing the use of thinner cross-members without compromising overall buckling resistance, thus improving energy density.
Data Source
AI summary
Disclosed is a battery, for an electric or hybrid vehicle, comprising:a casing defining a housing that extends in a longitudinal direction and a transverse direction,a plurality of cross-members attached to the casing and extending in the transverse direction between a first lateral edge and a second lateral edge of the casing, anda plurality of assemblies comprising electrochemical cells that extend successively in the transverse direction and are secured to one another,the cross-members and the assemblies being arranged successively against one other in the longitudinal direction in the housing so that there is no mechanical clearance between the cross-members and the assemblies, the assemblies and/or cross-members being attached to the casing.